Abstract: A high-durability printhead for an ink cartridge printing system. The printhead includes a substrate having ink ejectors (e.g. resistors) thereon and an orifice plate positioned above the substrate. The orifice plate has a top surface, bottom surface, and a plurality of openings therethrough. The orifice plate is optimally produced from a non-metallic organic polymeric composition. To improve the durability, heat-stability, and ink resistance of the printhead, an intermediate layer manufactured from a thermoplastic polyimide is employed between the orifice plate and the ink ejector-containing substrate. This particular system generally improves the structural integrity of the printhead and provides longer cartridge life.

Abstract: A novel polymeric orifice plate for a printhead. The plate includes a recess in the top surface thereof which terminates at a position between the top and bottom plate surfaces. The recess communicates with a bore which passes through the remainder of the plate and terminates at the bottom surface thereof. The recess has an upper end with a first opening therein, a lower end with a second opening therein, and a side wall which is preferably oriented at a right angle relative to the top surface of the plate. The recess may also have a bottom wall at the lower end. The first opening is larger than the second opening. The application of physical force to the plate does not disturb the second opening in the recess which is "inset" and protected. This design insures proper ink drop trajectory and the generation of high-quality printed images.

Abstract: A printhead for an inkjet printer employs an ink fill slot having an extended portion disposed as a depression on the primary surface of the printhead substrate. The barrier layer of the printhead forms the walls of the ink ejection chambers, the walls of and constrictions in the ink fill channels, and the contoured barrier lobes between the ink fill channels. The extended portion of the ink fill slot follows the contour of the barrier lobes such that the length of the substrate shelf between the ink fill channel constriction and the extended portion of the ink fill slot is equalized between ink ejection chambers.

Abstract: An ink fill slot can be precisely manufactured in a substrate utilizing photolithographic techniques with chemical etching, plasma etching, or a combination thereof. These methods may be used in conjunction with laser ablation, mechanical abrasion, or electromechanical machining to remove additional substrate material in desired areas. The ink fill slots are appropriately configured to provide the requisite volume of ink at increasingly higher frequency of operation of the printhead by means of an extended portion that results in a reduced shelf length and thus reduced fluid impedance imparted to the ink. The extended portion is precisely etched to controllably align it with other elements of the printhead.

Abstract: An ink fill slot can be precisely manufactured in a substrate utilizing photolithographic techniques with chemical etching, plasma etching, or a combination thereof. These methods may be used in conjunction with laser ablation, mechanical abrasion, or electromechanical machining to remove additional substrate material in desired areas. The ink fill slots are appropriately configured to provide the requisite volume of ink at increasingly higher frequency of operation of the printhead by means of an extended portion that results in a reduced shelf length and thus reduced fluid impedance imparted to the ink. The extended portion is precisely etched to controllably align it with other elements of the printhead.